U.S. patent application number 16/224609 was filed with the patent office on 2019-08-22 for extendable sleeve for poured concrete deck.
The applicant listed for this patent is Reliance Worldwide Corporation. Invention is credited to Larry D. Brown, James Cosley, Dennis Hart, Virgil O'Neil.
Application Number | 20190257082 16/224609 |
Document ID | / |
Family ID | 66992814 |
Filed Date | 2019-08-22 |
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United States Patent
Application |
20190257082 |
Kind Code |
A1 |
Brown; Larry D. ; et
al. |
August 22, 2019 |
EXTENDABLE SLEEVE FOR POURED CONCRETE DECK
Abstract
An improved cap and assembly is provided for a poured concrete
deck. The improved assembly has a diaphragm seal over-molded to a
top plate having a depending sidewall that is snap-fit to a base
containing a fire ring. A tubular sleeve is connected to the
over-molded top plate by snap fit connections to the sidewall and
by threaded fasteners passing through sockets in the sleeve,
sidewall and base. The over-molded diaphragm has a funnel shape. A
first sleeve cap has depending positioning tabs that may be broken
off to adjust the cap height relative to the sleeve, with an
inwardly extending latching surface engaging the sleeve when the
tabs are removed. A second cap has inwardly extending tabs that fit
into channels on the sleeve fit between ridges on the sleeve when
rotated to adjustably position the second cap on the sleeve.
Inventors: |
Brown; Larry D.; (Poway,
CA) ; Cosley; James; (Poway, CA) ; Hart;
Dennis; (Poway, CA) ; O'Neil; Virgil; (Poway,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Reliance Worldwide Corporation |
Poway |
CA |
US |
|
|
Family ID: |
66992814 |
Appl. No.: |
16/224609 |
Filed: |
December 18, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62609215 |
Dec 21, 2017 |
|
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62657519 |
Apr 13, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 1/948 20130101;
A62C 2/065 20130101; E04B 5/48 20130101; F16L 5/04 20130101; F16L
5/10 20130101 |
International
Class: |
E04B 5/48 20060101
E04B005/48; E04B 1/94 20060101 E04B001/94; A62C 2/06 20060101
A62C002/06; F16L 5/10 20060101 F16L005/10; F16L 5/04 20060101
F16L005/04 |
Claims
1. A diaphragm seal assembly for use with a base connected to a
tubular sleeve having a cylindrical wall with an internal diameter
D, the sleeve extending along a longitudinal axis for forming a
passage through a poured concrete deck formed on a support surface,
the assembly having a flexible diaphragm seal with a circular
opening on the longitudinal axis sized to allow passage of an
elongated member while flexibly engaging an outer surface of that
elongated member, comprising: an annular seal housing having a
sidewall extending along and encircling the longitudinal axis and
having an annular top plate extending inward toward the
longitudinal axis with a central opening at the axis that is larger
in diameter than the circular opening of the diaphragm seal, the
top plate having a surface which is textured and which encircles
the longitudinal axis; and wherein the flexible diaphragm seal has
an inner diameter defining the circular opening and also has an
over-molded outer diameter that extends over the textured surface
and around the longitudinal axis so that textured surface and top
plate are connected to the flexible diaphragm by over molding that
outer diameter to that textured surface.
2. The diaphragm seal assembly of claim 1, wherein the textured
surface is on a top surface of the top plate.
3. The diaphragm seal assembly of claim 1, wherein the top surface
extends radially inward.
4. The diaphragm seal assembly of claim 3, wherein the flexible
diaphragm has a funnel shape extending out of a plane orthogonal to
the longitudinal axis through the textured surface when the
diaphragm is in an undeformed condition.
5. The diaphragm seal assembly of claim 4, wherein the funnel shape
has straight walls forming a frusto-conical shape between the top
plate and the inner diameter of the diaphragm, and extends toward a
distal end of the tubular sleeve during use.
6. The diaphragm seal assembly of claim 4, wherein the funnel shape
has curved walls.
7. The diaphragm seal assembly of claim 6, wherein the curved walls
extend toward a distal end of the tubular sleeve during use.
8. The diaphragm seal of claim 4, wherein the seal housing sidewall
extends in an axial direction opposite the funnel shape.
9. The diaphragm seal assembly of claim 4, wherein the seal housing
sidewall has a plurality of latch members extending parallel to the
longitudinal axis in a direction away from a direction in which the
flexible diaphragm.
10. The diaphragm seal assembly of claim 4, wherein the seal
housing sidewall is connected to a base extending along the
longitudinal axis and enclosing a fire ring of intumescent material
that encircles the longitudinal axis.
11. The diaphragm seal assembly of claim 10, wherein the seal
housing sidewall connects to the base by a plurality of snap-lock
connections.
12. The diaphragm seal assembly of claim 11, further comprising a
plurality of threaded fasteners connecting the seal housing
sidewall to the base.
13. The diaphragm seal assembly of claim 11, further comprising the
tubular sleeve, with a plurality of threaded fasteners extending
between the tubular sleeve and the base.
14. The diaphragm seal assembly of claim 11, further comprising the
tubular sleeve, and wherein the tubular sleeve, seal housing
sidewall and base each have a socket, with a plurality of threaded
fasteners extending through the sockets to connect the tubular
sleeve, seal housing sidewall and base together.
15. The diaphragm seal assembly of claim 11, further comprising the
tubular sleeve, and wherein the tubular sleeve is connected to the
seal housing sidewall by snap lock connections, and wherein the
seal housing sidewall is connected to the base by snap lock
connections.
16. The diaphragm seal assembly of claim 14, further comprising the
tubular sleeve, and wherein the tubular sleeve is connected to the
seal housing sidewall by snap lock connections, and wherein the
seal housing sidewall is connected to the base by snap lock
connections.
17. The diaphragm seal assembly of claim 11, further comprising the
tubular sleeve, and wherein a bottom of the tubular sleeve has a
textured surface directly contacting the over-molded surface on the
outer diameter of the top plate.
18. The diaphragm seal assembly of claim 11, wherein the textured
surface comprises a plurality of concentric grooves.
19. The diaphragm seal assembly of claim 1, wherein the textured
surface comprises a plurality of concentric grooves.
20. The diaphragm seal assembly of claim 1, wherein a top surface
of the over-molded outer diameter has a plurality of generally
concentric grooves, axially opposite the textured surface.
21. A cap for a tubular sleeve having a cylindrical wall extending
along a longitudinal axis for forming a passage through a poured
concrete deck, the tubular sleeve having a plurality of radially
extending ridges separated into segments with a channel parallel to
the longitudinal axis separating each segment, the channel having a
circumferential width W, the external ridges spaced apart a
predetermined distance Z along the longitudinal axis, the tubular
sleeve having an inner diameter D, comprising: a cap having a
circular outer periphery with a generally flat top surface and a
flange depending from the outer periphery of the cap and encircling
the periphery of the cap, the depending flange having a bottom end;
at least one positioning tab extending inwardly from the bottom end
of the depending flange, the positioning tab having a bottom
surface that is orthogonal to the longitudinal axis during use, the
positioning tab having an inner surface that is inclined at an
acute angle to the bottom surface so the inner surface faces toward
an underside of the cap and toward the longitudinal axis, the
positioning tab being curved and having the same curvature as the
depending flange, the positioning tab having a width in the
circumferential direction which width is smaller than W and having
an axial length which length is smaller than Z so the positioning
tab may fit between two ridges of the sleeve and more easily slide
axially off any ridge engaged by the inclined surface.
22. The cap of claim 21 wherein the width is about W and the length
is about Z.
23. The cap of claim 22, wherein there are between two and six
positioning tabs equally spaced about a circumference of the
flange.
24. The cap of claim 21, further comprising an inner, depending
cylindrical flange having an outer diameter about D but slightly
smaller than diameter D.
25. The cap of claim 22, further comprising an inner, depending
cylindrical flange having an outer diameter about D but slightly
smaller than diameter D.
26. A cap for a tubular sleeve having a cylindrical wall extending
along a longitudinal axis for forming a passage through a poured
concrete deck, the tubular sleeve having a plurality of radially
extending ridges, with a first of the plurality of ridges located
an axial distance d from a distal end of the tubular sleeve that is
closest to the first of the plurality ridges, comprising: a cap
having a circular periphery with a cylindrical, depending flange at
the periphery and extending along the longitudinal axis during use,
the depending flange having external threads thereon, the cap
having a generally flat top surface; at least two curved position
stops depending from a bottom end of the depending flange and
connected to the depending flange by a weakened area extending
along the curvature of each position stop to make it easier to
break off the position stop from the depending flange, each of the
at least two position stops having the same axial length; a lip on
the inside of the depending flange extending inward and located
opposite the external threads, the lip having an inclined bottom
end facing downward and toward the longitudinal axis, the lip
having a flat surface opposite the inclined surface which flat
surface is generally orthogonal to the longitudinal axis to form a
catch, the flat surface located an axial distance slightly greater
than the distance d.
27. The cap of claim 26, wherein there are from two to six position
stops, each having an axial length of about 0.3 inches to about 1
inch and equally spaced about a circumference of the depending
flange.
28. The cap of claim 26, further comprising a plurality of
wrenching recesses in the top surface of the cap.
29. An assembly for forming a passage extending along a
longitudinal axis through a poured concrete deck formed on a
support surface and having an exterior deck surface, comprising: a
base containing a fire ring encircling the longitudinal axis, the
base having at least one fastener hole to connect the base to the
support during use; a tubular sleeve having a bottom connected to
the base to form at least a portion of the passage through the deck
during use, the sleeve having a top end with a first outer diameter
D1; a floor fitting having a top flange extending away from the
longitudinal axis, and having a bottom floor fitting tube having an
outer diameter D2, the floor fitting having a center of gravity
substantially centered on the longitudinal axis; a no-hub
connector, comprising a tubular body having opposing top and bottom
tubular body ends which are resiliently compressible, the bottom
floor fitting tube extending inside the top tubular body end and
the top end of the sleeve extending inside the bottom tubular body
end; a top ring clamp encircling the tubular body and compressing
the top tubular body end against the bottom floor fitting tube; a
bottom ring clamp encircling the tubular body and compressing the
bottom tubular body end against the end of the sleeve; and wherein
the base, sleeve and no-hub connector are self-supporting of the
floor fitting so the floor fitting top flange is substantially
perpendicular to the longitudinal axis.
30. The assembly of claim 29, further comprising a first threaded
fastener connecting the sleeve, top base and bottom base together
along a first threaded fastener axis, and a second threaded
fastener connecting the sleeve, top base and bottom base together
along a second threaded axis.
31. The assembly of claim 29, wherein the tubular body is about 4
to about 6 inches long.
32. The assembly of claim 29, further comprising a stiffening
sheath interposed between the ring clamp and the tubular body and
encircling the tubular body.
33. The assembly of claim 29, wherein D1 and D2 differ by no more
than about 10%.
34. The assembly of claim 29, wherein a single tubular sleeve
extends between the base and the no-hub connector.
35. The assembly of claim 29, wherein the tubular sleeve comprises
a first tubular sleeve is connected to the base and a second
tubular sleeve is connected to the no-hub connector, the first and
second sleeves being connected together by threaded fasteners.
36. The assembly of claim 29, wherein the base includes an upper
and lower base, connected together by snap-fit connections, with
the sleeve connected to the upper base by snap-fit connections.
37. The assembly of claim 36, wherein the lower base is connected
to a CD plate by at least one of a threaded fastener or a snap-fit
connection.
38. The assembly of claim 36, further comprising the poured
concrete deck with the flange substantially parallel to and located
at the exterior deck surface, and with no supporting struts or
wires in the concrete connecting the sleeve or floor fitting to the
support.
39. A kit for forming a tubular passage for poured concrete decks
formed on a support surface, comprising: an upper base having a
sidewall extending along and encircling a longitudinal axis and
having an annular top plate extending inward toward the
longitudinal axis with a central opening centered on that axis, the
top plate having a textured surface encircling the longitudinal
axis and an outer diameter of the top surface; and a flexible and
elastic diaphragm seal having an inner diameter defining a circular
opening centered on the longitudinal axis and smaller in diameter
than the central opening in the top plate, the diaphragm connected
to the top plate by over-molding an outer periphery of the flexible
diaphragm to that textured surface; a lower base encircling the
longitudinal axis and having fastener openings to fasten the lower
base to the support during use, the upper base and lower base
having a plurality of aligned snap-fit connections to connect the
lower base to the upper base during use; and a tubular sleeve
extending along the longitudinal axis during use, the tubular
sleeve having a top end and a bottom end, with the upper housing
sidewall and the bottom end of the sleeve having a plurality of
aligned snap-fit connections to connect the sleeve to the upper
base during use.
40. The kit of claim 39, further comprising a corrugated deck
plate, the lower base and corrugated deck plate having a plurality
of aligned snap-fit connections to connect the lower base to
corrugated deck plate during use.
41. The kit of claim 39, further comprising: a no-hub connector
having a deformable tubular body with top and bottom opposing ends,
and a top and a bottom ring clamp each sized to encircle the
respective top and bottom end of the tubular body during use, the
bottom end of the tubular body sized to enclose and be tightened
against the top end of the sleeve by the bottom clamp during
use.
42. The kit of claim 39, wherein the sleeve, upper base and lower
base each have a first socket which may be aligned along a first
fastener axis, and each have a second socket which may be aligned
along a second fastener axis; a first threaded fastener having a
length sufficient to pass through the first sockets when they are
aligned along the first fastener axis; and a second threaded
fastener having a length sufficient to pass through the second
sockets when they are aligned along the second fastener axis.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The application claims the benefit under 35 U.S.C. .sctn.
119(e) to Provisional Patent Application No. 62/609,215 filed Dec.
21, 2017, and Provisional Patent Application No. 62/657,519 filed
Apr. 13, 2018 the entire contents of which are incorporated herein
by reference.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not applicable.
BACKGROUND
[0003] An extendable tubular sleeve for poured concrete decks is
described in U.S. Pat. Nos. 9,086,174 and 9,103,116. But that
extendable sleeve uses a vertically-split base to connect to a
metal frame that supports intumescent rings and that
vertically-split base is cumbersome to assemble as it requires
threaded fasteners to hold the parts securely together and it
allows vertical misalignment of the vertically split parts of the
base. Moreover, a flexible diaphragm is clamped between a top of
the base and a sleeve that is threaded onto the base and the
threading rotation of the sleeve can damage the flexible diaphragm
and can also distort the diaphragm, thereby degrading the diaphragm
performance and sealing with the pipe passing through the sleeve
and diaphragm during use. For the above and other reasons, there is
a need for an improved extendable sleeve that is faster and easier
to assemble and that does not damage the diaphragm seal during
use.
[0004] The extendable tubular sleeve is adjusted in length by
cutting the inner sleeve to length and then putting on a cap to
prevent concrete from entering the sleeve as the sleeve is
entrained in concrete. But cutting the sleeve to length is time
consuming, inaccurate and cumbersome. There is thus a need for an
improved extendable sleeve that is easier to adjust in length.
[0005] Floor drain fittings are typically supported independently
of the extendable sleeves that form the bulk of the fluid passage
through concrete surfaces. This independent support is used because
the floor drain fittings are very heavy and require sufficiently
precise orientation and location that the extendable sleeves are
not used to support the fittings. There is thus a need for an
extendable sleeve that can be connected to and support a floor
drain fitting for a poured concrete slab.
BRIEF SUMMARY
[0006] An improved cap and assembly is provided for a poured
concrete deck. The improved assembly has a diaphragm seal
over-molded to a top plate having a depending sidewall that is
snap-fit to a base containing a fire ring. A tubular sleeve is
connected to the over-molded top plate by snap fit connections to
the sidewall and by threaded fasteners passing through sockets in
the sleeve, sidewall and base. The over-molded diaphragm has a
funnel shape. A first sleeve cap has depending positioning tabs
that may be broken off to adjust the cap height relative to the
sleeve, with an inwardly extending latching surface engaging the
sleeve when the tabs are removed. A second cap has inwardly
extending tabs that fit into channels on the sleeve fit between
ridges on the sleeve when rotated to adjustably position the second
cap on the sleeve.
[0007] There is also advantageously provided in improved cap for a
tubular sleeve having a cylindrical wall extending along a
longitudinal axis for forming a passage through a poured concrete
deck. The tubular sleeve has a plurality of radially extending
ridges separated into segments with a channel parallel to the
longitudinal axis separating each segment. The channel has a
circumferential width W with the external ridges spaced apart a
predetermined distance Z along the longitudinal axis and the
tubular sleeve has an inner diameter D. The improved cap may have a
circular outer periphery with a generally flat top surface and a
flange depending from the outer periphery of the cap and encircling
the periphery of the cap. The flange has a bottom with at least one
positioning tab extending inwardly from that bottom end of the
depending flange. The positioning tab has a bottom surface that is
orthogonal to the longitudinal axis during use and also has an
inner surface that is inclined at an acute angle to the bottom
surface so the inner surface faces toward an underside of the cap
and toward the longitudinal axis. The positioning tab is
advantageously curved and has the same curvature as the depending
flange. The positioning tab may further have a width in the
circumferential direction which width is smaller than W and also
has an axial length which length is smaller than Z so the
positioning tab may fit between two ridges of the sleeve and more
easily slide axially off any ridge engaged by the inclined
surface.
[0008] In further variations, the width of the positioning tab may
be about W and the length may be about Z. Optionally, there are
between two and six positioning tabs equally spaced about a
circumference of the flange, with three or four positioning tabs
preferred. The cap may also have an inner, depending cylindrical
flange having an outer diameter about D but slightly smaller than
diameter D of the sleeve so the inner flange fits inside the wall
forming the tubular sleeve. The cap thus may advantageously have
the diameter of the inner, depending cylindrical flange be about D
but slightly smaller than diameter D for a snug fit with the
cylindrical sleeve.
[0009] There is also provided a second cap for a tubular sleeve
having a cylindrical wall extending along a longitudinal axis for
forming a passage through a poured concrete deck. The tubular
sleeve has a plurality of radially extending ridges, with a first
of the plurality of ridges located an axial distance d from a
distal end of the tubular sleeve that is closest to the first of
the plurality ridges. The second cap has a circular periphery with
a cylindrical, depending flange at the periphery and extending
along the longitudinal axis during use. The depending flange has
external threads thereon to engage extension tubes or other parts.
The cap has a generally flat top surface to avoid excessive
entrainment in concrete and avoid catching on concrete finishing
tools. The second cap may also have at least two curved position
stops depending from a bottom end of the depending flange in order
to position the second cap a pre-determined distance above an
abutting ridge or flange on the mating sleeve. The second cap
advantageously has the depending flange connected to each position
stop by a weakened area extending along the curvature of each
position stop to make it easier to break off the position stop from
the depending flange and thus lower the height of the cap by the
axial length of the position stop. Each of the at least two
position stops have the same axial length. The second cap
advantageously has a lip on the inside of the depending flange and
extending inward and located opposite the external threads. The lip
may have an inclined bottom end facing downward and toward the
longitudinal axis so as to more easily fit onto an outwardly
extending flange. The lip has a flat surface opposite the inclined
surface which flat surface is generally orthogonal to the
longitudinal axis to form a catch with an outwardly extending
flange. The flat surface is advantageously located an axial
distance slightly greater than the distance d so the lip can engage
the outwardly extending ridge on the top of the sleeve in a
snap-fit or snap-lock engagement.
[0010] In further variations, the second cap may have from two to
six position stops, each having an axial length of about 0.25 to
about 1 inch and preferably, but optionally, equally spaced about a
circumference of the depending flange. The cap may further include
a plurality of wrenching recesses in the top surface of the
cap.
[0011] There is advantageously provided a diaphragm seal assembly
for use with a base connected to a tubular sleeve having a
cylindrical wall with an internal diameter D. The sleeve extends
along a longitudinal axis for forming a passage through a poured
concrete deck. The assembly has a flexible diaphragm seal with a
circular opening on the longitudinal axis sized to allow passage of
an elongated member while flexibly engaging an outer surface of
that elongated member. The diaphragm seal assembly includes an
annular seal housing having a sidewall extending along and
encircling the longitudinal axis and having an annular top plate
extending inward toward the longitudinal axis with a central
opening at the axis that is larger in diameter than the circular
opening of the diaphragm seal. The top plate has a surface which is
textured and which encircles the longitudinal axis. The flexible
diaphragm seal has an inner diameter defining the circular opening
and also has an over-molded outer diameter that extends over the
textured surface and around the longitudinal axis so that textured
surface and top plate are connected to the flexible diaphragm by
over molding that outer diameter to that textured surface. This
provides a unitary connection of the seal to the seal housing
rather than a clamped assembly as in the prior art.
[0012] In other variations, the diaphragm seal assembly has the
textured surface on a top surface of the top plate, although the
textured surface could be on the bottom of the top slate with the
flexible seal extending through the central opening of the top
plate. The top surface and top plate advantageously extend radially
inward, but could be inclined upward or downward.
[0013] The flexible diaphragm may have a funnel shape extending out
of a plane orthogonal to the longitudinal axis through the textured
surface when the diaphragm is in an undeformed condition, with the
top plate inclined upward or downward, or with the top plate in a
plane orthogonal to the longitudinal axis. The funnel shape may
have straight walls forming a frusto-conical shape between the top
plate and the inner diameter of the diaphragm. The frusto-conical
shape may advantageously extend toward a distal end of the tubular
sleeve during use. The funnel shape may have curved walls. The
curved walls may extend toward a distal end of the tubular sleeve
during use.
[0014] The diaphragm seal assembly may have the seal housing
sidewall extends in an axial direction opposite the funnel shape,
or extend in the same direction as the funnel shape. The seal
housing sidewall may have a plurality of latch members extending
parallel to the longitudinal axis in a direction away from
direction in which the flexible diaphragm extends. The seal housing
sidewall may be connected to a base extending along the
longitudinal axis and enclosing a fire ring of intumescent material
that encircles the longitudinal axis. The seal housing sidewall may
also be connected to the base by a plurality of snap-lock
connections. The snap-lock connections may include elongated latch
members having barbed ends to engage catches in recesses on the
base being preferred to connect the parts. But other male-female
connections can be used. The assembly may also include a plurality
of threaded fasteners connecting the seal housing sidewall to the
base. The assembly may include the tubular sleeve, with a plurality
of threaded fasteners extending between the tubular sleeve and the
base. The assembly advantageously includes the tubular sleeve, with
the tubular sleeve, seal housing sidewall and base each having a
socket, and with a plurality of threaded fasteners extending
through the sockets to connect the tubular sleeve, seal housing
sidewall and base together.
[0015] Advantageously, the textured surface comprises a plurality
of concentric grooves. Further, a top surface of the over-molded
outer diameter may have a plurality of generally concentric
grooves, axially opposite the textured surface. Advantageously, the
assembly includes the sleeve and a bottom of the sleeve is
textured, preferably with concentric ridges, which textured sleeve
bottom abuts the over-molded outer diameter of the top plate.
[0016] There is also advantageously provided an assembly for
forming a passage extending along a longitudinal axis through a
poured concrete deck formed on a support surface and having an
exterior deck surface. The assembly advantageously includes a base
containing a fire ring encircling the longitudinal axis where the
base has at least one fastener hole to connect the base to the
support during use. A tubular sleeve having a bottom is connected
to the base to form at least a portion of the passage through the
deck during use. The sleeve has a top end with a first outer
diameter D1. A floor fitting is connected to the sleeve. The floor
fitting has a top flange extending away from the longitudinal axis
and a bottom floor fitting tube with an outer diameter D2. The
floor fitting has a center of gravity substantially centered on the
longitudinal axis. A no-hub connector connects the sleeve to the
floor fitting. The no-hub connector includes a tubular body having
opposing top and bottom tubular body ends which are resiliently
compressible. The bottom floor fitting tube extends inside the top
tubular body end and the top end of the sleeve extends inside the
bottom tubular body end to provide a fluid connection. A top ring
clamp encircles the tubular body and compresses the top tubular
body end against the bottom floor fitting tube. A bottom ring clamp
encircles the tubular body and compresses the bottom tubular body
end against the end of the sleeve. The ring clamps are typically
hose clamps or other adjustable length, clamping fasteners. The
base, sleeve and no-hub connector are self-supporting of the floor
fitting so the floor fitting top flange is substantially
perpendicular to the longitudinal axis, without the use of any
braces, wires or support struts extending between the support on
which the concrete is poured and the base, sleeve and no-hub
connector.
[0017] In further variations, the assembly may include a first
threaded fastener connecting the sleeve, top base and bottom base
together along a first threaded fastener axis, and optionally
connecting those parts to the support. The assembly may also
include a second threaded fastener connecting the sleeve, top base
and bottom base together along a second threaded axis, and
preferably further connecting those parts to the support onto which
the concrete is poured to form the deck.
[0018] In still further variations on this assembly, the tubular
body is advantageously about 4 to about 8, and more preferably
about 4 to 6 inches long. A stiffening sheath may be interposed
between the ring clamp and the tubular body and encircling the
tubular body. Advantageously, diameters D1 and D2 differ by no more
than about 10%. Preferably, a single tubular sleeve extends between
the base and the no-hub connector, but for thicker concrete decks
the tubular sleeve may include a first tubular sleeve connected to
the base and a second tubular sleeve connected to the no-hub
connector, with the first and second sleeves being connected,
preferably by threaded fasteners. The assembly may include any or
all of the base and diaphragm variations described herein,
including an upper and lower base connected together by snap-fit
connections, with the sleeve connected to the upper base by
snap-fit connections, or with the lower base is connected to a CD
plate by at least one of a threaded fastener or a snap-fit
connection.
[0019] The resulting concrete deck advantageously has the flange
substantially parallel to and located at the exterior deck surface,
with no supporting struts or wires in the concrete connecting the
sleeve or floor fitting to the support. The absence of these
supporting or stabilizing structures provides for a more uniform
concrete interlock surrounding the passage through the concrete
deck and avoids crack-inducing and rust-inducing struts, wires and
braces passing as odd angles through the concrete to various parts
of the tubular passage through the deck.
[0020] There is also advantageously provided a kit for forming a
tubular passage for poured concrete decks formed on a support
surface. The kit may include an upper base having a sidewall
extending along and encircling a longitudinal axis and having an
annular top plate extending inward toward the longitudinal axis
with a central opening centered on that axis. The top plate
advantageously has a textured surface encircling the longitudinal
axis and an outer diameter of the top surface. A flexible and
elastic diaphragm seal has an inner diameter defining a circular
opening centered on the longitudinal axis and smaller in diameter
than the central opening in the top plate. The diaphragm is
connected to the top plate by over-molding an outer periphery of
the flexible diaphragm to that textured surface. The kit also
includes a lower base encircling the longitudinal axis and having
fastener openings to fasten the lower base to the support during
use. The upper base and lower base may have a plurality of aligned
snap-fit connections to connect the lower base to the upper base
during use. The kit also advantageously includes a tubular sleeve
extending along the longitudinal axis during use. The tubular
sleeve has a top end and a bottom end. The upper housing sidewall
and the bottom end of the sleeve each have a plurality of aligned
snap-fit connections to connect the sleeve to the upper base during
use.
[0021] In further variations, the kit may include the various other
parts described herein. The kit may include, for example, a
corrugated deck plate, with the lower base and corrugated deck
plate having a plurality of aligned snap-fit connections to connect
the lower base to corrugated deck plate during use. The kit may
advantageously include a no-hub connector and even a floor fitting.
The no-hub connector may have a deformable tubular body with top
and bottom opposing ends. A top and a bottom ring clamp are
included with or on the no-hub connector and each ring clamp is
sized to encircle the respective top and bottom end of the tubular
body during use. The bottom end of the tubular body is sized to
enclose and be tightened against the top end of the sleeve by the
bottom ring clamp during use.
[0022] The kit may also have the tubular sleeve, upper base and
lower base provided with a first socket which may be aligned along
a first fastener axis, and each have a second socket which may be
aligned along a second fastener axis. The kit also advantageously
includes a first threaded fastener having a length sufficient to
pass through the first sockets when they are aligned along the
first fastener axis as well as including a second threaded fastener
having a length sufficient to pass through the second sockets when
they are aligned along the second fastener axis. The fastener
length is sufficient to extend beyond the sockets a distance
sufficient to fasten those connected parts together or to fasten
those connected parts to a CD plate or to the support onto which
concrete is poured to form the deck.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] These and other advantages and features of the invention
will be better appreciated in view of the following drawings and
descriptions in which like numbers refer to like parts throughout,
and in which:
[0024] FIG. 1 shows an exploded perspective view of an expandable
sleeve assembly;
[0025] FIG. 2 shows a top view of the assembly of FIG. 1;
[0026] FIG. 3 shows a sectional view of the assembly of FIG. 1,
taken along section 3-3 of FIG. 2;
[0027] FIG. 4 shows an exploded perspective view of a fire ring and
intumescent rings held within the fire ring;
[0028] FIG. 5 shows a top, perspective view of a lower base;
[0029] FIG. 6 shows a bottom perspective view of the lower base of
FIG. 5;
[0030] FIG. 7 shows an exploded perspective view of a lower base
and upper base and seal assembly
[0031] FIG. 8A is a top view of an assembly of the lower and upper
base seal assembly and an inner sleeve;
[0032] FIG. 8B is a sectional view of the assembly of FIG. 8A,
taken along section 8B-8B of FIG. 8A;
[0033] FIG. 8C is an enlarged portion of FIG. 8B, taken along
section 8C-8C of FIG. 8B,
[0034] FIG. 8D is an enlarged view of the lower right portion of
FIG. 8B, showing a latch and catch connection between the upper
base and seal assembly and the lower base assembly;
[0035] FIG. 9A is an upper perspective view of the upper base and
seal assembly and its flexible diaphragm;
[0036] FIG. 9B is a lower perspective view of the upper base and
seal assembly of FIG. 9A;
[0037] FIG. 9C is a side view of the upper base and seal assembly
of FIG. 9A;
[0038] FIG. 9D is a top view of the upper base and seal assembly of
FIG. 9C;
[0039] FIG. 9E is a bottom view of the upper base and seal assembly
of FIG. 9C;
[0040] FIG. 10A is an upper perspective view of an inner
sleeve;
[0041] FIG. 10B is a lower perspective view of the inner sleeve of
FIG. 10A;
[0042] FIG. 10C is a side view of the inner sleeve of FIG. 10A;
[0043] FIG. 10D is a top view of the inner sleeve of FIG. 10C;
[0044] FIG. 10E is a bottom view of the inner sleeve of FIG.
10C;
[0045] FIG. 11A is a top view of a first safety cap on an outer
sleeve and showing a lower base;
[0046] FIG. 11B is a sectional view taken along 11B-11B of FIG. 11A
showing a first safety cap on an outer sleeve, an inner sleeve, an
upper base and seal assembly, a lower base and an aerator box below
the lower base;
[0047] FIG. 11C is an enlarged view taken from FIG. 11B, showing
how the inner sleeve may seal against the diaphragm on the upper
base and seal assembly;
[0048] FIG. 12A is a top view of an inner sleeve on an upper base
and seal assembly that is connected to a lower base;
[0049] FIG. 12B is a partial sectional view taken along section
12B-12B of FIG. 12A;
[0050] FIG. 12C is an enlarged view of a portion of FIG. 12B,
showing how the inner sleeve may connect to the upper base and seal
assembly;
[0051] FIG. 12D is a full sectional view taken along section
12D-12D of FIG. 12A, showing a flange on the inner sleeve resting
on a stop on the upper base and seal assembly;
[0052] FIG. 12E is an enlarged portion of FIG. 12D showing the
flange on the inner sleeve resting on a stop on the upper base and
seal assembly;
[0053] FIG. 13A is an exploded perspective view of an assembly
having an adapter to change diameter and extend the length of the
sleeve assembly and a cap on the adapter;
[0054] FIG. 13B is a top view of the assembly of FIG. 13A;
[0055] FIG. 13C is a section of the assembly of FIG. 13A, taken
along section 13C-13C of FIG. 13B;
[0056] FIG. 13D is an enlarged upper corner of FIG. 13C showing the
cap engaging the adapter;
[0057] FIG. 14A is an exploded perspective view of an assembly
having a second cap on the inner sleeve;
[0058] FIG. 14B is a top view of the assembly of FIG. 14A;
[0059] FIG. 14C is a sectional view of the assembly of FIG. 14A,
taken along section 14C-14C of FIG. 14B;
[0060] FIG. 14D is an enlarged upper corner of FIG. 13C showing the
second cap engaging the adapter;
[0061] FIG. 15A is an exploded perspective view showing the inner
sleeve and a short, larger diameter adapter;
[0062] FIG. 15B is a top view of the assembly of FIG. 15A;
[0063] FIG. 15C is a sectional view of the assembly of FIG. 15A
taken along section 15C-15C of FIG. 15B;
[0064] FIG. 15D is an enlarged view of the connection between the
short adapter and the inner sleeve;
[0065] FIG. 16 is an exploded perspective view of the short adapter
of FIG. 15A on an outer sleeve;
[0066] FIG. 17 is an exploded perspective view of an assembly
having a drain fitting, no-hub connector and a sleeve assembly;
[0067] FIG. 18 is a perspective view of the assembly of FIG.
17;
[0068] FIG. 19A is a top view of the assembly of FIG. 18;
[0069] FIG. 19B is a sectional view of the assembly of FIG. 18
taken along section 19B-19B of FIG. 19A;
[0070] FIG. 20A is a top perspective view of a filament
assembly;
[0071] FIG. 20B is a bottom perspective view of the filament
assembly of FIG. 20A
[0072] FIG. 21A is a top view of an upper and lower base on a CD
plate;
[0073] FIG. 21B is a partial sectional view taken along section
21B-21B of FIG. 21A; and
[0074] FIG. 21C is an enlarged portion of FIG. 21B showing an
interconnection between the CD plate and lower base.
DETAILED DESCRIPTION
[0075] As used herein, the following part numbers refer to the
following parts: 20--extendable sleeve assembly; 22--CD Plate;
24--opening in CD plate; 26--lower base; 27--base threads;
28--socket in lower base; 30--catches in lower base; 32--fire ring;
34--intumescent members; 36--upper base and seal assembly; 38--ring
tab; 40--fingers on ring; 42--flange; 44--latch; 46--upper base
sockets; 50--top plate; 52--inner flange; 54--flexible diaphragm;
56--diaphragm sidewall; 58--indentations; 59--position stop;
60--inner sleeve; 62--base of inner sleeve; 64--sleeve flange;
66--sealing projections; 70--first set of ridges; 72--second set of
ridges; 74a, 74b--channels; 76--end segments; 78--engaging
protrusion on end segment 76; 80--whisker support; 81--whisker
assembly; 82--whiskers; 84--whisker base; 86--male whisker
connector; 88--female whisker connector; 92--inner sleeve socket;
94--sleeve latch members; 96--catch; 98--outer sleeve; 99--ridges;
100--engaging posts; 102--first safety cap; 104--radial sockets;
106--external threads; 108--internal threads; 110--external
threads; 112--stop tab; 114--wrenching recesses; 116--lip on first
cap; 120--second cap; 122--outer cap flange; 124--positioning tab;
126--inclined top surface; 128--bottom surface of tab; 130--inner
cap flange; 140--floor fitting; 142--floor fitting tube or spigot;
144--top flange of floor fitting; 146--no hub connector; 148--ring
clamps; 150--cylindrical body; 160--adapter; 162--external adapter
threads; 164--positioning tabs; 166--outwardly extending portion;
168--larger diameter wall; 170--aerator box; and 172--flange on
bottom of aerator box.
[0076] The depicted adjustable expandable sleeve assembly is
configured for axial assembly using snap-fit connections, with
optional threaded fasteners being used to further connect and
secure the upper base to the lower base and tubular sleeve. As used
herein, the relative directions up and down, upward and downward,
above and below are with respect to the vertical axis when the
expandable tubular sleeve assembly in vertically orientated for
installation on a horizontal floor, as generally shown in the first
figure showing the parts in an exploded view along the straight,
longitudinal axis 21. The relative directions inward and outward
are with respect to a longitudinal axis of the tubular sleeve
assembly in the vertical orientation as shown in the first,
exploded view of the drawings.
[0077] Referring to FIGS. 1-20, an extendable tubular sleeve
assembly 20 extends along longitudinal axis 21 and is optionally
connected to a corrugated deck ("CD") plate 22 which is preferably
large enough to extend across corrugations of corrugated metal
forms used for poured concrete floors. The CD plate has various
openings 24. The plate 22 is shown as a rectangular plate with a
large circular opening for a pipe and other components described
later. The plate 22 is sturdy enough to support the extendable
tubular sleeve on the corrugated form and is typically made of
sheet metal with stamped perforations forming the openings 24. When
the CD plate 22 is not used, the lower base 26 is fastened to
another support, typically a plywood sheet. During use, concrete is
poured onto the support to which the sleeve assembly 20 is
fastened, entraining the sleeve assembly in the concrete. When the
concrete hardens, a passage through the poured deck is formed by
the sleeve assembly 20, allowing elongated members to pass through
the deck, such as plumbing pipes, electrical conduits, electrical
wires, fiber optic wires, etc. to pass through the hardened
concrete deck.
[0078] The extendable sleeve assembly 20 may include a lower base
26, upper base and seal assembly 36, an inner sleeve 60, and either
one of a first or second cap 102, 120, and optionally outer sleeve
98, as described later. The extendable sleeve assembly has a lower
base 26 that is optionally connected to the plate 22 by threaded
fasteners, such as screws, that pass-through openings 24 to fasten
the base 26 and extendable sleeve assembly 20 to the corrugated
form. The lower base 26 has a central opening for a pipe and
several openings or lower base sockets 28 for receiving threaded
fasteners and several openings forming catches 30 (FIG. 8D). The
central opening is defined by a short flange encircling the axis
21, with base threads 27 on the flange and encircling the axis
21.
[0079] A fire ring 32 configured to hold one or more intumescent
members 34 is held between the lower base 26 and an upper base and
seal assembly 36. FIGS. 1, 4 and 11B-11C show two intumescent
member 34a, 34b shaped as nested, concentric rings having a
rectangular cross-section. The fire ring 32 is preferably of metal
or other material that resists high temperatures. The fire ring is
preferably a metal ring with a central opening and outwardly
extending ring tabs 38 that are long enough to be entrained in
concrete during use. A plurality of fingers 40 extend upward from
the inner edge of the ring that defines the opening in the ring.
The intumescent members 34a, 34b nest inside the fingers 40 with
the fingers preventing lateral movement while the bottom of the
intumescent members 34 rest on the annular base of the fire ring
32.
[0080] The upper base and seal assembly 36 may be referred to
herein as upper base 36, with both names referring to the same
construction. The upper base and seal assembly 36 has a downward
depending flange 42 forming a seal housing sidewall, having a
plurality of downwardly extending latches 44. The latches 44 are
long enough to engage the catches 30 in the lower base 26 to
connect the upper base and seal assembly 36 to the lower base 26 by
axial motion (FIG. 1). The flange 42 forms a seal housing sidewall
that fits around the outer periphery of the outer intumescent
member 34b with the fire ring 32 sandwiched between the flange 42
of the upper base and seal assembly, and the lower base 26.
Advantageously, the seal housing sidewall formed by sidewall 42 is
preferably cylindrical and has a bottom that traps the outwardly
extending ring tabs 38 between the bottom of the flange and the top
of the lower base 26. A plurality of upper base sockets 46 are
preferably formed on the outer periphery of the seal housing
sidewall formed by sidewall 42 and have passages aligned with the
sockets 28 in the lower base 26 so threaded fasteners can pass
through the aligned sockets and secure the upper base and seal
assembly 36 to the lower base 26 (FIGS. 8B, 8E). The sockets 46, 28
and threaded fasteners are optional.
[0081] The upper base and seal assembly 36 has an inwardly
extending top plate 50 at the upper end of the of the assembly 36,
with a depending inner flange 52 forming an opening that is
preferably circular. The top plate 50 and inner flange 52 and outer
sidewall of the upper seal assembly form an inverted, U-shaped
cross-section. The top plate 50 extends over the top of the
intumescent member 34 to restrain upward motion of the intumescent
members 34a, 34b. The inner flange 52 is preferably a generally
cylindrical flange (continuous or intermittent) and aligned with
the fingers 40, or extends slightly inward of those fingers (FIG.
1). Thus, a pipe inserted from below the lower base will be guided
by the fingers through the opening formed by the inner flange 52
without the edge of the pipe damaging the inner flange 52. A pipe
inserted from above the lower base will be guided by the inner
flange 52 so as to avoid an edge of the pipe engaging and damaging
an end of the fingers 40.
[0082] A flexible diaphragm 54 is over-molded onto the top plate
50. The flexible diaphragm has an inner opening that is preferably
circular and is formed of an elastic material, including neoprene,
rubber, or other stretchable materials. The opening in the
diaphragm 54 is preferably smaller than the intended outer diameter
of pipe passing through the extendable sleeve assembly 20 is
intended. The sleeve assemblies 20 are designed for various pipe
diameters so the designed pipe diameter is known in advance. The
diaphragm 54 preferably has a flexible, annular portion surrounding
the opening in the diaphragm, with the opening advantageously being
formed by a flat-sided, conical sidewall or formed by a curved
sidewall 54 (FIGS. 9C, 11B). As best seen in FIG. 11C, the outer
periphery of the top plate 50 may have concentric circular
indentations or other indentations 58 forming a labyrinth pattern,
with the outer periphery of the flexible diaphragm 54 being
over-molded into those indentations. The indentations 58 and
over-molding provide a labyrinth seal to help provide a fluid tight
connection with the upper base 36 on the bottom side of the
diaphragm 54. A position stop 59 (FIGS. 9A and 12E) extends
(preferably axially) along a portion of the seal housing sidewall
formed by sidewall 42 to help position an inner sleeve 60 as
described later.
[0083] Referring to FIGS. 1, 10-12, 14, 15 and 17-19, an inner
tubular sleeve 60 has a tubular, cylindrical shape, with a base 62
configured to rest on top of the outer portion of the upper base
and seal assembly and also extend downward over the seal housing
sidewall formed by sidewall 42. To improve the fluid seal between
the base 62 of inner tubular sleeve 60 and the diaphragm 54, the
bottom of the base 62 may have raised ridges 66, preferably
comprising concentric circular ridges, that embed themselves in the
more flexible material of the over-molded diaphragm 54, at the
outer periphery of the diaphragm.
[0084] Preferably, as seen in FIG. 12E, a radially outwardly
extending sleeve flange 64 on a lower end of the tubular sleeve and
base abuts position stop 59 on the seal housing sidewall formed by
sidewall 42 of the upper base and seal assembly to position the
inner tubular sleeve 60 axially relative to the upper base 36 and
lower base 26.
[0085] The inner sleeve 60 has first and second sets of
spaced-apart, outwardly extending ridges 70, 72 forming intervening
slots between the respective ridges of each set. The first ridges
70 and intervening first slots each extend about half way around a
first side or first partial circumference of the inner sleeve 60.
The second set of ridges 72 and second slots between those second
ridges extend about half way around the opposing, second side or
second partial circumference of the inner tubular sleeve 60. The
ridges 70, 72 on the first and second sides of the inner sleeve 60
are equally spaced apart about the distance of a saw blade used by
construction workers. The first set of ridges 70 are offset from
the second set of ridges 72, with the first set of ridges
preferably being spaced in fractions of an inch and the second set
of ridges being preferably spaced metrically, preferably in
millimeters. Visible indicia (not shown) on the inner sleeve 60
discloses a distance from the bottom of the lower base 26 to each
slot, or to the bottom of each ridge (70, 70) forming the slot, so
that a worker can cut the inner sleeve 60 to desired, known length
by cutting at a slot, with the saw blade guided by the opposing
ridges 70, 72 on each side of the slot. The ridges may be viewed as
graduations on the outside of the inner sleeve 60. The ridges 70,
72 and printed indicia identify a plurality of graduated distances
from the bottom of the lower base 26. These ridges and grooves are
known and described in more detail in U.S. Pat. No. 9,086,174 and
U.S. Published Application No. 2015/0121783, the complete contents
of which are hereby incorporated by reference.
[0086] The first and second sets of ridges 70, 72 and their
intervening slots are in radially aligned planes extending
orthogonal to axis 21. These sets of ridges 70, 72 are separated by
first and second longitudinal channels 74a, 74b located on opposing
sides of the inner tubular sleeve 60. As desired, the printed
indicia may be located in one or both longitudinal channels 74a,
74b, or on the outer sides of inner sleeve 60 in the spaces between
adjacent ridges 70, 72. The ends of two adjacent ridges 70 or two
adjacent ridges 72 within each set of ridges may be joined by
axially extending end segments 76 (FIGS. 10C, 18), with alternating
pairs of ridges joined by offset end segments 76 that are offset
circumferentially a short distance from end segments 76 each other
to form staggered axial end connections. A latching protrusion 78
(FIGS. 14A, 17-18) may extend axially from or near the axially
extending end segments 76 to form a snap lock connection described
later. The ridges 70, 72 are parallel to each other with the ridges
70 being offset axially relative to the ridges 72. By cutting the
inner sleeve 60 off at a particular ridge 70, 72, or the slot
associated with that particular ridge, a user can determine the
maximum height of the extendable sleeve assembly 20 and thus adjust
the length of the sleeve
[0087] Referring to FIGS. 10A-10B, 14A, 15A and 18, the inner
tubular sleeve 60 optionally has one or more whisker supports 80
extending outwards from the sleeve 60, preferably at the bottom of
the sleeve 60 and more preferably from the outer portion of the
sleeve by the base 62. A whisker assembly 81 having a plurality of
flexible, elongated whiskers 82 (FIGS. 20A-20B) mounted to a
whisker base 84 having a male (protruding) whisker connector 86 on
a bottom of the base, releasably fasten or connect to one of the
whisker supports 80. The whisker supports 80 have a female
(recessed) whisker connector 88. The whisker connectors 86, 88
releasably engage to hold the whisker assembly 81 to the whisker
support 80. The male and female connectors 86, 88 may be on
opposing parts (support 80 or whisker assembly 81) and of varying
configurations to releasably engage. The connectors 86, 88 allow a
user to manually attach a whisker assembly to the whisker support
or manually remove the whisker assembly from the support. The
whisker base 84 may optionally have one or more axial,
through-holes so threaded fasteners may be used to optionally
secure the whisker assembly to the safety cap 102 as described
later.
[0088] Referring to FIGS. 10A-10B, 14A, 15A and 18, the inner
sleeve 60 advantageously has at least one, and preferably has a
plurality of inner sleeve sockets 92 connected to the bottom of the
inner sleeve, preferably connected adjacent the base 62 and
extending outward of the sleeve flange 64. The inner sleeve sockets
92 preferably align with the lower base sockets 28 and the upper
base sockets 46 so threaded fasteners can pass through the aligned
sockets and secure the inner sleeve 60, upper base 36 lower base 26
together (FIGS. 8B, 8E). The threaded fasteners through the aligned
sockets also urges the sealing projections 66 against the outer
periphery of the flexible diaphragm 54 to form and maintain a fluid
tight seal between those parts. The sockets 28, 46 and 92 and
threaded fasteners are optional, but preferable. The threaded
fasteners passing through each set of aligned sockets 28, 49 and 92
advantageously extend along a fastener axis, with a different
fastener axis extending along each set of aligned sockets and each
fastener axis advantageously but optionally spaced symmetrically
about the longitudinal axis or spaced equally around a common
circumference centered on longitudinal axis 21. symmetrically
Advantageously, one of the sockets 92 is immediately adjacent
whisker support 80, at least one of which is vertically aligned
with the channels 74 or end segments 76.
[0089] Extending outward from the bottom portion of the inner
sleeve 60 are a plurality of sockets 92. The sockets 92 preferably
have a passed therethrough sized to accept a threaded fastener. The
sockets 92 preferably extend radially outward and at locations
selected to align with sockets 28 in the lower base 26 and sockets
46 in the upper base and seal assembly 36. Threaded fasteners may
pass through the aligned passages in the sockets 92, 46 and 28 to
fasten together the outer sleeve 60, upper and lower bases 36 and
26. The threaded fasteners (FIGS. 8B, 8E) provided an increased
stability and strength that helps maintain the integrity of the
connected parts in the rough construction environment.
[0090] Depending downward from the bottom portion of the inner
tubular sleeve 60, and preferably extending downward from the
sleeve flange 64, are at least one and preferably a plurality of
sleeve latch members 94. The sleeve latch members are located to
axially engage recesses or catches 96 (FIGS. 12B-12C) formed in the
upper base and seal assembly 36 to hold those parts together. In
the depicted embodiments, the latch members 94 are male latch
members with an outwardly facing barb and engage female catches 96
or female latch members having a ridge, lip or inwardly facing barb
to engage the male latch member (FIGS. 12B-12C). The latches 94 and
catches 96 allow axial movement of the inner sleeve 60 and upper
base and seal assembly 36 to fasten the parts together using a
snap-fit connection. The latches are preferably sufficient to hold
the parts together for the intended use without the threaded
fasteners passing through the sockets as described above.
[0091] Referring to FIGS. 11B and 13, an outer tubular sleeve 98 is
optionally provided. The outer sleeve 98 is a tubular sleeve with
ridges 99 extending outward from the exterior of the sleeve. If
multiple extensions are to be used, the ridges 99 may comprise the
sets of ridges 70, 72 described on the inner sleeve 60, or an
extension may be threaded into the top end of the outer sleeve 98
using internal threads 108 described later. The ridges 99 are
preferably circumferential ridges, equally spaced. The ridges 99
stiffen the sleeve and engage the poured concrete during use. The
outer sleeve 98 is larger in diameter than the inner sleeve 60 and
fits over the inner sleeve 60 to form nested, coaxial sleeves. For
example, the inner sleeve 60 may have a 5-inch inner diameter and
the outer sleeve 98 may have a 5.5-inch diameter. Advantageously,
the whisker support 80 extends far enough away from the generally
cylindrical wall of the inner sleeve 60 that the outer sleeve fits
between the cylindrical wall of the inner sleeve 60 and the outer
whisker assembly 81 when connected to the whisker support.
[0092] The outer tubular sleeve 98 has a plurality if engaging
posts 100 extending radially inward. The engaging posts 100 are
preferably aligned in vertical columns and spaced vertically apart
a distance corresponding to the location of the end segments 76 and
adjacent grooves 70, 72 forming those end segments, both on the
inner sleeve 60, so the engaging posts can fit between the ends of
adjacent grooves 70 or 72. The engaging posts 100 are vertically
aligned in groups and each group of engaging posts 100 is spaced
circumferentially apart a distance corresponding to the
circumferential location of the channels 74. The number of groups
of engaging posts 100 preferably corresponds to the number of
channels 74, but may be as small as one group of vertically aligned
engaging posts. In use, each group of engaging posts may be aligned
with and moved vertically along a different one of the channels 74
until a desired height of the outer sleeve 98 and safety cap 102 is
reached, at which point the outer sleeve and inner sleeve are
rotated relative to each other so the engaging posts 100 fit
between the adjacent ends 76 of a set of ridges 70 or 72. The
ridges 70, 72 are slightly offset adjacent the end segments 76 and
the latching protrusion 78 may engage and hold the engaging post in
position. The offset allows the adjacent ridges 70 or 72 to guide a
saw blade in the groove between the adjacent ridges, while the
offset avoids the cut and allows enough structure to engage the
engaging ends 100 and maintain the position.
[0093] A plurality of radially oriented sockets 104 are formed in
the wall of the outer tubular sleeve and preferably have a radial
passage extending through the socket. In use, a threaded fastener
may be screwed through each radial socket 102 to secure the outer
sleeve to the inner sleeve. The threaded fasteners extending
through the radial sockets 104 provide a stronger connection than
the engagement of the engaging posts 100 and ends of the adjacent
ridges 70, 72. During use in construction, the extended sleeve
assembly may be hit by workers or equipment from various directions
and the threaded connection achieved by the radial sockets 104
helps maintain the height of the sleeve assembly once it is
set.
[0094] The outer tubular sleeve 98 has external threads 106 on its
lower end which can threadingly engage base threads 27 during use,
and in that use the end of the outer sleeve 98 with threads 106
will be at the top of the outer sleeve 98 with the outer sleeve
below the base 26. The outer sleeve 98 has internal threads 108 on
its upper end, preferably formed on the inside of a slightly offset
flange of slightly larger diameter than the outer sleeve 98. The
slightly offset flange preferably forms a shoulder 109 (FIG. 13A,
13D).
[0095] Referring to FIGS. 1-3, 11B, and 13A-13C, a first cap, a
safety cap 102, has external threads 110 on its outward facing edge
and a plurality of depending, stop tabs 112. The external threads
110 are configured to threadingly engage internal threads 108 on
outer tubular sleeve 98. The safety cap 102 is advantageously
configured so its top surface is flush with the top of the outer
sleeve 98 during use. The tabs 112 are sized so that when the top
surface of the safety cap 102 is flush with the top edge of the
outer sleeve 98, the ends of tabs 112 abut the flange 109. Thus,
the flange 109 acts as a position stop for the tabs 112 and safety
cap 102. There are preferably at least two stop tabs 112, and
advantageously from two to eight stop tabs 112, each stop tab
extending an axial distance of about 0.25 to 1 inch. The external
threads 110 are few in number and preferably comprise multiple lead
threads, such as double lead threads that extend about three times
around the circumference of the cap. The safety cap 102 has a
plurality of wrenching recesses 114 so a wrenching tool (not shown)
can engages the recesses and remove the cap after the extendable
sleeve is encased in concrete. The safety cap 102 has a female
whisker connector 88 in its top surface, preferably in a centrally
located recess, so that whisker assembly 81 may be connected to the
top of the safety cap 102.
[0096] In some cases, the concrete is very thin and a very low
height is required for the inner extension tube 60. In order to
accommodate thin slabs 2.5-3.5 inches thick, the first cap 102 has
external threads 110 that are few in number, preferably about 3-4
complete threads. The stop tabs 112 may be broken off so that the
height or thickness of the first cap along axis 21 is the same as
that of the flange containing the 3-4 threads. Referring to FIG.
13D, the first cap has an inwardly extending lip 116 having an
inclined lower surface and a flat top surface to form a catch. The
lip 116 can be continuous or intermittent. The inner sleeve 60 is
cut to the desire length and the first cap 102 pushed over the open
end of the sleeve, with the lip 116 located to engage one of the
ridges 70, 72 extending outwards from the first sleeve 60. The lip
116 is located a distance from the inside surface of the top of the
first cap 102 so that the lip 116 can engage one of the ridges 70,
72. This leaves the external threads 110 exposed to the concrete
and those threads are entrained in the poured concrete. After the
concrete hardens, a pipe may be pushed from the bottom of the
sleeve assembly upward against the inside surface of the first cap
102 with enough force to either disengage the lip 116 from the
engaged ridge 70, 72, or to shear the lip off, or to deform the lip
enough that the cap can be removed from the hardened concrete.
[0097] As best seen in FIG. 13D, the lip 116 on the inside of the
depending flange of the cap 102 extends inward and is located
opposite the external threads 110. The lip 116 has an inclined
bottom end facing downward and toward the longitudinal axis 21 so a
ridge 70, 72 of a tubular sleeve can more easily slide past the lip
to engage the catch formed by an orthogonal surface on the lip. The
flat surface forming the catch is located an axial distance from
the bottom, inside surface of the cap sufficient to engage and
catch one of the ridges 70, 72. Thus, if the ridges 70, 72 are
located a distance d from the adjacent distal end of the tubular
sleeve from which the ridges extend, the flat surface of the lip
116 forming the catch is located a distance slightly greater than
the distance d (to account for the thickness of the ridge 70, 72)
to engage the closest of the ridges during use when the cap 102 is
placed onto the tubular sleeve having such ridges.
[0098] In use, the intumescent material 34 is placed on the fire
ring 32, guided by fingers 40. The fire ring 32 and intumescent
material 34 is placed on the lower base 26 and then the upper base
and seal assembly 36 is placed over the intumescent material 34 and
latches 44 on the upper base assembly 36 engage catches 30 in the
lower base to fasten the upper and lower bases together, trapping
the fire ring and intumescent material between the upper and lower
bases. The latches 44 engage catches 30 through relative axial
movement of the upper base and seal assembly 36 and the lower base
26. The inner tubular sleeve 60 is placed over the upper base and
seal assembly 36 and latches 94 on the inner sleeve 60 engage
catches 96 on the upper base and seal assembly 36 as seen in FIG.
12C, to connect the inner sleeve to the upper base--through
relative axial movement of the parts. The latches 94 and catches 96
hold the sealing projections 66 against the outer periphery of the
diaphragm 54 to provide a fluid tight seal. Optional but preferably
threaded fasteners pass through sockets 28, 46, 92 (FIGS. 8B, 8E)
to secure the upper and lower bases 36, 26 together and to hold the
intumescent material and fire ring in position with the ring tabs
38 extending outward a distance sufficient to be entrained in
concrete during use. By entraining the ring tabs 38 in concrete,
the intumescent material 34 is maintained in position even if the
plastic used in the sleeve assembly 20 (especially bases 26, 36)
and plumbing pipes melts or is burnt away. The fasteners passing
through sockets 92 also more securely hold the inner sleeve 60 to
the upper and lower bases 36, 26.
[0099] The outer sleeve 98 is connected to the inner sleeve 60 by
aligning engaging posts 100 with channels 74 and moving the sleeves
60, 98 relative to each other until a desired height of the sleeve
assembly 20 is achieved, at which point the outer and inner sleeves
are rotated to engage the posts 100 with the selected adjacent
grooves 70, 72 separated by end segments 76. Engaging protrusions
78 engage and hold the engaging posts 100 in position. Threaded
fasteners through radial sockets 104 securely connect the inner and
outer tubular sleeves 60, 98, respectively. The safety cap 102 is
screwed onto the end of the outer sleeve 98. The distance from the
bottom of the lower base 26 to the top of the outer sleeve 98 and
safety cap 102 is thus predetermined. The whisker assembly 82 is
removed from the support 80 and optionally connected to the
connector 88 in the outside of the safety cap 102. The lower base
26 is fastened to a concrete support--typically by nails or screws
passing through the base. As desired, the lower base 26 may be
connected to CD plate 22 which in turn is fastened to a support
such as a corrugated support by threaded fasteners. The lower base
26 is connected to the CD plate 22 or other support by threaded
fasteners, or snap-lock mechanisms. The assembly 20 is then
entrained in concrete, with the whisker assembly extending above
the finished concrete surface to identify the location of the cap
102 and assembly 20 after the concrete surface is finished and
hardened. The safety cap 102 is removed for use of the entrained
sleeve assembly 20. A pipe is inserted through the opening in the
flexible diaphragm 54 either from the top of the assembly, or from
the bottom of the assembly, with the diaphragm resiliently urged
against the outer surface of the pipe by the difference in sizes
between the pipe and the opening in the diaphragm.
[0100] The above description provides an extended length sleeve
assembly for thick concrete floors. For concrete floors with a
smaller thickness a different cap may be used. Concrete floors with
a thickness of 7.5 inches, 7.75 inches and 8 inches are common. It
is cumbersome and labor intensive for a user to manually cut the
inner sleeve 60 to the specific length needed for a particular
concrete floor at a jobsite, and to do so accurately. If the
tubular sleeve is cut too short, the entire sleeve cannot be used
for that floor thickness and must be discarded to laboriously saved
and inventoried for potential use with a different floor thickness.
Sometimes the cap on the end of existing sleeves may have a
threaded connection which allows the top surface of the cap to be
extended above the top edge of the sleeve--but that provides a
continuously variable height adjustment which is difficult to
measure and which may be inadvertently changed if workers contact
and rotate the cap (thereby changing its height). The second cap
120 provides an incremental adjustment for the height.
[0101] Referring to FIGS. 14A-14D, a second, incrementally
positionable cap 120 is provided having a flat top, wrenching
recesses 114 and female whisker connector 88--just as first cap
102. But the second cap 120 has a depending outer cap flange 122 at
its outer periphery with at least one, and preferably a plurality
of pairs of positioning tabs 124. The positioning tabs 124 may
extend radially inward toward axis 21 and are located a
predetermined distance below the top surface of the second cap 120.
The positioning tabs 124 preferably have a top surface 126 that is
inwardly and downwardly inclined and a flat bottom surface 128. The
inclined top surface 126 is inclined at an acute angle relative to
the bottom surface 128 so the inclined surface 126 faces an
underside of the second cap 120. The positioning tabs 126 are sized
to fit between the ridges 70, 72 and into the slots between those
ridges.
[0102] During use, the tab 124 fits between two adjacent ridges in
one of the sets of ridges 70 or 72. The flat bottom 182 rests on
the lower of two adjacent ridges in the group of ridges 70 or 72 so
that a downward force on the cap 120 presses the tab 126 against
the lower of the two adjacent ridges to maintain the position of
the cap and the inner tubular sleeve 60 to which the cap is
connected. The tabs 124 are located to be spaced circumferentially
around the outer cap flange a distance corresponding to the
circumferential spacing of the vertical channels 72. The inner
sleeve 60 is cut to the rough height needed--but at a location so
that the total height of the lower base 26, upper base 36 and inner
sleeve 60 is less than the slab thickness. The second cap 120 is
rotated so the tabs 126 are aligned with different ones of the
vertical channels 74a, 74b and the cap is then positioned axially
relative to sleeve 60 so the tabs align with a pair of adjacent
ridges in groups of ridges 70, 72, and the cap is then rotated so
the tabs 126 slide into the space or groove between the desired
ridges. Because the top of the second cap 120 is a known distance
from the tabs 126 and the bottom surface 128 of the tabs, the
location of the top surface of the cap 120 is also known. The
ridges 70, 72 are preferably spaced in increments that allow the
position of cap 120 to be manually adjusted to vary the total
height of the sleeve assembly 20 to be 7.5, or 7.75 or 8 inches,
preferably by engaging the tabs with three different, vertically
adjacent ridges 70, 72 in the groups of ridges.
[0103] The tabs 124 are preferably at the bottom of the outer cap
flange and the length of the flange determines how many grooves
between the ridges 70, 72 may be engaged. The outer cap flange is
preferably about 0.5 to 1-inch long. A longer length of outer cap
flange limits the minimum height of the sleeve assembly 20. The
shorter length flange (0.5 to 1 inch) allows adjustment for the
most common thicknesses of the concrete floor. Advantageously, the
flange is from 0.1 to 0.5 times the length of the inner sleeve 60.
Optionally, radial flange sockets can be formed in the outer cap
flange so threaded fasteners can be screwed through the outer cap
flange and into the inner sleeve 60.
[0104] The upper surface of the positioning tabs 126 are inwardly
and downwardly inclined so that they more easily slide off the
upper ridge 70, 72 adjacent the tabs. After the concrete is poured
and hardened, the outer cap flange is embedded in the concrete. A
pipe may be inserted from below, through the diaphragm 54 and
against the inside of the second cap 120 to force the cap out of
the concrete. As seen in FIGS. 14A and 14D, the cap 120 preferably
has an inner cap flange 130 radially inward from the outer cap
flange 122 and parallel thereto and concentric therewith. The inner
cap flange 130 is located to fit inside the inner surface of the
inner tubular sleeve 60, preferably very close to that surface
without binding. The inner flange 122 extends downward a distance
that is about where the positioning tab 126 begins. As a pipe is
pushed upward through the adjustable sleeve assembly and against
the bottom of the second cap 120, the positioning tabs 124 will
either shear off because of the concrete that fills the grooves
between ridges 70, 27, or the positioning tabs 124 will deform and
urge the top portion of the inner sleeve 60 inward. The inner
flange 130 forms a ring that helps strengthen the top portion of
the inner sleeve 60 and helps prevent the tabs 124 from pushing the
top portion of the inner sleeve 60 inward and cracking the concrete
or breaking the top portion of the inner sleeve. The inner flange
130 is believed optional, but is preferred.
[0105] The cap 120 thus has a circular outer periphery with a
generally flat top surface and flange 120 depending from the outer
periphery of the cap and encircling the periphery of the cap. The
cap 120 is removed after the concrete deck is poured and
advantageously, the top surface of the cap is at or very near the
surface of the concrete deck so that little or no concrete overlays
the cap 120. A "generally flat" top surface helps reduce the
entrainment of the cap 120 and avoids outwardly extending
protrusions that can engage the rotating blades of finishing
trowels or other concrete finishing equipment, but allows recesses.
The positioning tab 124 has a bottom surface that is orthogonal to
the longitudinal axis 21 during use. The positioning tab 124 has a
width that is smaller than the circumferential space W between the
end segments 76 which forms a channel on the outer surface of the
sleeve, which channel is generally parallel to the axis 21. The
axial length of the positioning tab 124 is smaller than the axial
distance between the outwardly extending ridges 70, 72 between
which the positioning tab 124 fits during use. Advantageously there
are between two and six positioning tabs, spaced so each tab fits
along a different one of the channels between the end segments 76.
The inner, depending cylindrical flange 130 has an outer diameter
slightly smaller than the inner diameter of the tubular sleeve to
which the cap 120 fastens.
[0106] Referring to FIGS. 17-19, the extendable sleeve assembly 20
may be used with a no-hub connector 146 and a plumbing floor drain
fitting 140 (e.g., drain fitting, toilet drain fitting) with a top
flange 144 and a lower drain tube or spigot 142 to provide a
sufficiently rigid assembly to be used in construction and while
concrete is poured to entrain the parts. Currently, the extendable
sleeve assembly 20 is fastened to a concrete form by screwing or
nailing the lower base 26 to the concrete form, or fastening the
lower base 26 to a CD plate 22 which is in turn nailed or screwed
or otherwise fastened to a concrete form. After the extendable
sleeve assembly 20 is fastened to a concrete form and adjusted to
its desired height, a floor drain fitting 140 is positioned on top
of the sleeve assembly 20 and held in position by metal rods and
wires positioned in whatever way the user decides is most expedient
to support the floor drain in position until the concrete is poured
and hardened. Because these floor drain fittings 140 are heavy,
typically of cast iron, the required support for these fittings is
sturdy so as to position and support the floor drain fitting
independent of the sleeve assembly 20. Typically, the floor drain
fitting 140 has a lower tube 142 that fits inside the inner tubular
sleeve 60 or outer tubular sleeve 98. Occasionally, the lower tube
142 abuts the end of those sleeves 60, 98 but that is undesirable
because a good fluid connection is not ensured and pushing downward
on the sleeve assembly 60 may cause it to tile and misalign,
allowing concrete to enter the passage formed by the sleeve
assembly. The floor fittings 140 are typically symmetric about the
longitudinal axis 21.
[0107] The assemblies of FIGS. 1-16 and especially 17-19 may use a
no-hub connector 146 to securely fasten the floor fitting 140 to
the top of the sleeve assembly 20 such that the sleeve assembly
self supports the drain fitting during pouring of the concrete and
finishing with no support struts, wires or braces extending between
the support on which the concrete is poured and any part of the
base, sleeve, no-hub connector or floor fitting to stabilize the
parts as concrete is poured, finished and sets. The no-hub
connector 146 may have a cylindrical body with opposing ends and a
radially compressing mechanism at each opposing end to move the
ends radially inward to seal against another part. The depicted
no-hub connector 146 is a tubular body 150 with inwardly deformable
ends. A ring clamp 148 encircles each end of the tubular body 150.
More than one ring clamp may be used on each end of the tubular
body. A thick, rubber hose is typically used to form the body 150,
with a thick, stiff hose, and/or a metal sheath around the tube and
between the ring clamps to stiffen the body 150 at the central part
of the body. The metal sheath typically comprises a cylindrical
shape with a lengthwise slot to allow the diameter to change as the
connector is tightened, and with outwardly curved or rolled ends to
avoid cutting into connected parts. A first end of the connector
146 fits over the outer end of the inner tubular sleeve 60 (or
outer tubular sleeve 98) and a second end of the connector 146 fits
over the tube 142 of the floor drain fitting 140. The ring clamps
148 are tightened to squeeze the body 150 against the sleeve 60 (or
98) and tube 142 to form a tight connection. A slotted metal sheath
may encircle the tubular body and the slot allows the sheath to
contract as the ring clamps are tightened, with the metal sheath
providing axial support to stabilize the floor fitting.
[0108] In the described embodiments for use with the sleeve
assembly 20, the no-hub connector 146 allows a small lateral offset
of the joined tubes, allows a small axial offset of the joined
tubes, and allows tubes of different diameter to be joined if the
difference in diameters is small enough, all while maintaining a
desired alignment of the parts. The body 150 is advantageously of
rubber, EDPM, polyisoprene, including silicon rubber, or other
suitably stiff but resiliently deformable materials that are stiff
enough and optionally have a high enough sliding friction
coefficient to maintain the position and orientation of the clamped
tubular parts without noticeable creep when creep is measured over
a few days. Thus, the position and orientation of a floor fitting
140 having a lateral dimension of about 12 inches, is believed to
be maintained within about 0.1 inch of the initial position when
concrete is poured and within about 0.15 inches after finishing,
along the X axis, along the Y axis, and along the Z axis.
[0109] The length of the no-hub connector 146 and the stiffness of
the connector are selected to provide a sufficiently strong and
stiff support that the weight of the floor drain fitting 140 may be
supported in its use position by the no-hub connector--without the
need for further support as in the prior art, from, for example,
support wires or struts on the floor drain fitting 140. Thus, the
floor drain fitting 140 is supported on the support sheet or
corrugated deck onto which the concrete deck is poured, only by the
base (26, 36 and 22 if a CD is used), sleeve 60 and the no-hub
coupler 146. The normal connection of the base 26, 36 or other base
to the support (typically plywood or CD) onto which the concrete is
poured is believed sufficient, such as nails or threaded fasteners
or bolts on CD. As desired, additional fasteners may be used to
connect the base 26 or CD plate 22 to the support onto which
concrete is poured to form the concrete deck. But no external
braces, wires or support struts extending between the support on
which the concrete is poured, and the parts of the tubular passage
formed by the base, sleeve(s), no-hub connector and floor
fitting.
[0110] The top flange 144 typically has plumbing connections on it
and must be parallel to the concrete surface, and the no-hub
connector 146, sleeve 60 and base 26, 36, must maintain the desired
position and orientation of the floor drain fitting 140. The floor
drain fitting 140 is typically made of cast iron and very heavy and
the no-hub connector 60 must maintain the desired position and
orientation of the floor drain fitting 140. Advantageously,
[0111] Advantageously, the diameter of the inner tubular sleeve 60
is selected to be about the same diameter of the no hub connector
146 so that a body 150 of uniform diameter may be used for the
connector 146. In this context, "about the same diameter" means
within 10% of the largest outer diameter. Thus, if the largest
outer diameter of two tubes is 2 inches, about the same diameter
allows a plus or minus 0.2 inch variation between the two tubes. If
the differences between the floor drain fitting outlet tube 142 and
the tubular sleeves 60, 93 are great enough then a connector 146
may be selected which has a body 150 that changes diameter from one
end to the other, although advantageously a change in diameter of
more than one inch is not desirable. The threaded fasteners
extending through the lower base sockets 28, the upper base sockets
46, and the sockets 92 on the sleeve 60, connect the sleeve and
base together to form a strong and stiff structure that is believed
to help maintain the position and orientation of the floor fitting
140 and its top flange 144. Securing the threaded fasteners passing
through these sockets 28, 46 and 92 to the support onto which the
concrete is poured to form the deck, anchors these connected base
and sleeve parts to provide a sturdy support for the no-hub
connector 146 and floor fitting 140.
[0112] The assembly and use sequence is modified slightly when a
floor fitting 140 is supported by the sleeve assembly 20 as no cap
102 or 120 is required because the floor fitting 140 is connected
by the no-hub connector 146 to the top end of the sleeve 60 or to
any extended sleeve as by outer sleeve 98. But the floor fitting
itself is covered to prevent concrete from entering it so a cap or
cover of sorts is provided and that floor fitting cover may have be
configured to have the whisker assembly 81 removably connected to
the fitting cover so the cover may be more easily located after
finishing of the concrete. The floor fitting cover is
advantageously flat (excluding the whisker assembly connected to
the cover) so it does not engage the concrete finishing tools and
mar the concrete surface or be damaged by those finishing
tools.
[0113] If only the inner sleeve 60 is used, then the floor fitting
140 has its tube or spigot 142 fit inside the top end of the no-hub
connector 146 while the top end of the sleeve 60 fits inside the
bottom end of the no-hub connector 146. The ring clamps 148 are
then tightened while the floor fitting 140 is held in its desired
position and orientation. Advantageously the top flange 144 is
parallel with the anticipated exterior surface of the concrete
deck, and the floor fitting tube or spigot 142 and no hub connector
146 are both aligned with the longitudinal axis, as is the sleeve
60 and base parts 26, 46. The base 26 is fastened to the support
and concrete is poured onto the support, advantageously with the
floor fitting 140 covered so concrete does not enter it during
pouring the concrete deck or finishing the exterior surface of the
deck.
[0114] This assembly of the floor fitting 140, no-hub connector
146, sleeve 60, along with the upper and lower base 36, 26 is
advantageously arranged and aligned along a common longitudinal
axis 21 while the lower base 26 is fastened to the support onto
which the concrete is poured to form the deck. That support is
typically a series of plywood sheets, a metal CD, or other support.
Alternatively, the assembly of the floor fitting 140, connector
146, sleeve 60 and base parts 26, 36 may be created and connected
separately, and then fastened to the support onto which the
concrete deck is poured, be it, by fastening the lower base 26 to
the support.
[0115] The lower base 26, upper base and seal assembly 36 and inner
tubular sleeve are connected axially by latch and catch, snap-fit
connections. Preferably, the lower base 26 also connects to the CD
plate 22 by latch and catch, snap-fit connections. The threaded
fasteners may be used to provide a more secure connection, but may
be omitted. Advantageously though, the sleeve 60, upper base 36 and
lower base 26 are connected not just by snap-fit connections, but
are further connected by threaded fasteners through the sockets 92,
46 and 28 in those respective parts. A threaded fastener such as a
bolt with one end above socket 92 and the other end below base 26
and socket 28 may be used to interconnect these parts and hold them
securely together, and the connected parts may then be fastened to
the support for the concrete deck by fasteners passing through the
lower base 26. Alternatively, one head of the bolt may be on the
bottom side of the support for the poured concrete deck, be that a
sheet of plywood or a corrugated deck ("CD") to fasten the base and
sleeve more directly to the support for the poured concrete. To
fasten the sleeve assembly to the support for the concrete deck
does not require a bolt, as a threaded fastener such as a screw may
pass through the sockets 92, 46 and 28 and also through the support
for the poured concrete deck, be that a sheet of plywood or a
corrugated deck ("CD") so as to more directly fasten the sleeve 60,
and housing parts 26, 36 together and to the support for the
concrete surface. These above connections may be used regardless of
whether a floor fitting 140 is used.
[0116] If the poured deck is thicker than provided by the base
parts 26, 36, sleeve 60, no-hub fitting 150 and floor fitting 140,
the length may be increased by either or both of using a longer
no-hub connector 146 or adding a second sleeve. Advantageously, the
no-hub connector 146 is relatively short, typically four 4 to 8
inches long and advantageously about 4 to 6 inches long. The longer
connectors 146 use multiple ring clamps 148 on each end of the
connector. A stiffening sheath of metal or plastic may be used
between the ring clamps 148 and body 150 to stiffen the no-hub
connector 146 and stabilize the floor fitting 140. If the body 150
is thicker and the stiffening sheath strong enough, a few inches of
length may be obtained by using a stiffening sheath on the no-hub
connector. Even if added length is not needed, the stiffening
sheath may be used to further strengthen and stiffen the no-hub
connector.
[0117] Alternatively, a thicker deck with the fitting assembly 20
supporting the floor fitting 140 may be achieved by using an
extended sleeve, such as the second sleeve 98. The connection
between inner sleeve 60 and the outer sleeve 98 must be
sufficiently strong and stiff to support the added weight of the
floor fitting 140 without additional stabilizing and support
devices such as wires, rods, etc. A sufficiently strong and stable
connection is believed to be formed providing mating threads on
mating ends of the inner and outer sleeves for an incremental
extension of length, or by fitting the outer sleeve over the inner
sleeve and using the engaging posts 100 mating with ridges 170, 172
to adjust the length, and then using threaded fasteners passing
through radial sockets 104 to interconnect the overlapping portions
of the inner and outer sleeves.
[0118] The diameter of the end of the sleeve 60, 98 and the
diameter of the floor fitting tube or spigot 142 are advantageously
about the same. Any slight differences in diameter may be
accommodated by combining inner and outer sleeves 60, 98,
recognizing that outer sleeve 98 is slightly larger in diameter
than inner sleeve 60, and using threaded fasteners to connect the
two sleeves allows not only an adjustable length but a strong and
stable interconnection between the sleeves. Further adjustment in
diameter may be achieved by using the adaptor 160, described above,
which may have a selected outer diameter. Radial sockets 104 may be
provided to the adaptor 160, to the top portion of inner sleeve 60,
or to both to accommodate threaded fasteners passing through the
adaptor 160 and into the sleeve 60 to interconnect, strengthen and
stabilize the connection. The no-hub connector 146 may also
accommodate some change in diameter, and if a connector 146 is used
with a non-uniform diameter along the length of its body 150, then
advantageously the bottom end of the no-hub connector 146 is of
larger diameter than the top end of the connector 146, with the
ring clamps 148 being of appropriate diameter for use with the
respective connector ends of different diameter.
[0119] After the extendable sleeve assembly 20 is connected to the
no-hub connector 146 and floor fitting 140, and the base 26 or CD
plate 22 is connected to the support onto which the concrete is
poured, the height and orientation of the floor fitting and any
flange 144 is set, by moving the extendable sleeve assembly, the
no-hub connector 146 and floor fitting. The extendable sleeve
assembly 20 is believed to be sufficiently stiff and stable when
fastened to the support onto which concrete is poured that it
doesn't shift laterally or angularly, and it allows a stable height
adjustment and position to be set. The no-hub connector 146 allows
some small adjustment in height and allows adjustment in
orientation of the floor fitting flange 144, with tightening of the
ring clamps 148 fixing the orientation and height. The resulting
assembly, when tightened and positioned, is believed sufficiently
stable to allow concrete to be poured and entrain the assembled and
oriented parts and to maintain the alignment and orientation of the
parts as the concrete cures and is finished--without the need for
additional wires or inclined support struts to brace the heavy
floor fitting in position. The base, sleeve and no-hub connector
are thus self-supporting of the floor fitting so the floor fitting
top flange is substantially perpendicular to the longitudinal axis.
The impact forces of workers hitting the sleeve assembly 20
supporting the floor fitting 140 may shift the position or
orientation of the floor fitting, thus, the orientation and
position are advantageously checked shortly before pouring concrete
to entrain the fitting assembly and floor fitting. The that
position and orientation are believed to be maintained during
pouring and curing of the concrete, and absent unusual
circumstances, during finishing of the concrete surface.
[0120] The floor fitting flange 144 is typically substantially
perpendicular to the longitudinal axis. The floor fitting flange
144 may be slightly inclined as the exterior surface of the
concrete deck may be slightly inclined by about 1-3.degree. for
drainage, and "substantially perpendicular" is used to encompass
this variation for drainage. If the floor fitting 140 is
intentionally orientated with the flange 140 at a greater
inclination, the sleeve assembly 20 and no-hub connector 140
described herein are believed sufficient to maintain that
orientation. The sleeve assembly 20 and no-hub connector 140 are
not intended for supporting the floor fitting 146 at any
appreciable distance offset laterally from the longitudinal axis or
for supporting a floor fitting 146 that is sufficiently asymmetric
that it has its center of gravity offset substantially from the
longitudinal axis 21. It is believed the sleeve assembly 20 and
no-hub connector 140 can support a floor fitting 140 of 50 pounds
with a center of gravity offset laterally a distance of about 0.5
inches from the longitudinal axis 21. But preferably the weight and
center of gravity offset from the longitudinal axis 21 are about 25
pounds or less, offset laterally about 0.5 inches or less. When the
center of gravity of the floor fitting is within the above offset
distances, the floor fitting is substantially centered on the
longitudinal axis 21. There is thus provided a method and apparatus
for self-supporting a floor fitting by an extendable sleeve
assembly using a no-hub connector, during pouring of the concrete,
and advantageously during finishing of the concrete surface.
[0121] Referring to FIGS. 15-16, an adapter 160 is shown for
changing the diameter of the extendable sleeve assembly 20. The
adapter has a first end with external adapter threads 162 and
inwardly extending positioning tabs 164. An outwardly extending
portion 166 shown as a radial extending shoulder which then extends
upward to form larger diameter sidewall 168 of the adapter. The
positioning tabs 164 are located circumferentially to fit into
vertical columns 74. The positioning tabs 164 slide vertically in
columns 74 until the top of the adaptor is at the desired height
and then the adaptor is rotated about axis 21 to fit the
positioning tabs 164 into the desired space between the groups of
ridges 70, 72 on the outside of the inner tubular sleeve 60. This
arrangement allows a larger diameter than the inner sleeve 60 to be
attached to the inner sleeve.
[0122] As seen in FIGS. 15-16, the adapter 160 may be inverted so
that the external adapter threads 162 engage the internal threads
108 on the top end of the outer tubular sleeve 98. In this
orientation, the adapter 160 provides a larger diameter sleeve on
the end of the outer sleeve 98. The adapter 160 has a fixed height,
but the overall height of the sleeve assembly 20 may be adjusted by
adjusting the position of the outer sleeve 98 on the inner sleeve
60.
[0123] Referring to FIGS. 11A-11B, an optional aerator box 170 bay
be releasably connected to the bottom of the lower base 26. The
lower base 26 has internal threads 27 (FIG. 3) which may
threadingly engage external threads on the upper end of the aerator
box 170. The aerator box 170 has an outwardly extending flange 172
with optional fastener holes in the flange. Fasteners may connect
the aerator box 170 to a concrete form to position the intumescent
ring 34 further into the thickness of the concrete slab or deck,
and to allow an enlarged recess or cavity on what is typically the
lower surface of the slab or deck. The general configuration of the
aerator box 170 may be cylindrical or it may have various flat
sided shapes, or combinations of curved and flat sides.
[0124] Referring to FIGS. 21A-21C, the CD plate may have various
upward extending projections 180 each fitting into a different one
of plural slots 182 in the lower base 26 in order to interconnect
the CD plate 22 and lower base 26. The projections 180 are
preferably upwardly bent portions of a metal CD plate 22 or molded
projections of a plastic CD plate and restrain relative lateral
movement and rotation in the plane of the CD plate between the
lower base 26 and the CD plate 22. Other connections could be used,
including threaded fasteners to interconnect the parts.
[0125] There is advantageously provided a method of forming a fluid
passage through a concrete deck poured onto a support using an
extendable sleeve assembly 20 and to self-support a floor fitting
140 with a flange 144 at the finished concrete surface using the
fitting assembly 20 and a no hub-connector 146. The lower base is
fastened to the upper base and seal assembly 36 by snap lock
fittings and then fastened to the support onto which the concrete
is poured. If that support is a corrugated deck that the lower base
26 is snap fit to CD plate 22. If that support is the typical
plywood support than fasteners are passed through fastener holes in
the base 26, where the fasteners typically comprise threaded
fasteners or nails. The sleeve 60 may be snap-fit to the upper base
and seal assembly 36 before after the lower base 26 is connected to
the support onto which the concrete is poured. As needed, an outer
sleeve 98 or an adapter 160 is connected to the base or the sleeve
60, advantageously using threaded connections or threaded fasteners
as described herein. Advantageously, threaded fasteners pass
through aligned sockets 28, 46, 29 and into or CD plate 22 or the
support onto which concrete is poured. A cap 102, 120 is placed
over the open end of the extendable sleeve assembly 20. The height
of the sleeve 60 or 98 is adjusted to the desired height, the
vertical alignment of axis 21 is checked and the parts adjusted as
needed--although only small adjustments are needed. One or more
wedges may be inserted between the base and support or the CD plate
and the support to adjust the orientation of axis 21. The cap may
be added before or after the height adjustment. The whisker
assembly 81 is likewise connected to the cap sometime before
concrete is poured. After verifying alignment to the extent needed
(not all decks require the same alignment), the concrete is poured,
the concrete surface finished and the slab or deck of concrete is
allowed to cure enough to walk on, preferably without marking the
surface permanently. The whiskers identify the location of the cap,
which is usually flush with the concrete surface or slightly below
the concrete surface. The cap is removed, typically by pushing it
upward and off by inserting a pipe from below and through the
fitting assembly 20.
[0126] If a drain fitting 140 is used, then the assembly 22 is as
above, it the cap 102, 120 are omitted and a different cap, shaped
to connect to and extend over and cover the parts of the drain
fitting which are to be exposed after the concrete is finished. The
floor fitting cover is not described in detail but such covers are
known in the art. The above method adds a no-hub coupling 146 to
the top end of the extendable sleeve assembly, whether that top end
is formed by the inner sleeve 60, the outer sleeve 98, or the
adapter 160. The bottom end of the tubular body 150 fits over the
top end of the sleeve, 60 or 98 or fits over the adapter 160 while
the top end of the tubular body 150 fits over the floor fitting
tube or spigot 142, and the ring clamps 148 are tightened. The
floor fitting 140 may be connected to the no-hub connector 146
before or after connector 146 is connected to the extendable sleeve
assembly 20. As the ring clamps 198 are tightened height, location
and orientation of the floor fitting 140 and its top flange 144 are
checked and adjusted as needed, with the ring clamps 148 tightened
to hold the floor fitting and its flange in the desired position.
No wires, support struts or brackets are believed needed to
maintain the position of the floor fitting 140 and its top flange
144. Depending on the activity around the assembly or how long it
has been since the assembly was aligned, the position of the floor
fitting and its top flange may be rechecked shortly before concrete
is poured. Concrete is then poured, finished and the concrete deck
or slab cured until it can be walked on without permanent
deformation of the surface. The cover over the floor fitting 140 is
then removed, either from the exterior, finished surface of the
concrete or by pushing a rod through the extendable sleeve assembly
20, no-hub fitting 146 and floor fitting 140. When the floor
fitting 140 is connected to the extendable sleeve assembly, it is
preferred to have threaded fasteners pass through aligned sockets
28, 46, 29 and into or CD plate 22 and/or into the support onto
which concrete is poured to connect the parts to the support.
[0127] The various parts of the sleeve assembly 20, the no-hub
coupling 146 and even the floor fitting 140 may all be included in
a kit, or any subset of these parts may be included in a kit.
[0128] As required, detailed embodiments of the present invention
are disclosed herein; however, it is to be understood that the
disclosed embodiments are merely exemplary of the invention, which
may be embodied in various forms. Therefore, specific structural
and functional details disclosed herein are not to be interpreted
as limiting, but merely as a basis for the claims and as a
representative basis for teaching one skilled in the art to
variously employ the present invention in virtually any
appropriately detailed structure.
[0129] The above description is given by way of example, and not
limitation. Given the above disclosure, one skilled in the art
could devise variations that are within the scope and spirit of the
invention, including various ways of configuring the latch members
and catches that hold the parts together. Further, the various
features of this invention can be used alone, or in varying
combinations with each other and are not intended to be limited to
the specific combination described herein. Thus, the invention is
not to be limited by the illustrated embodiments.
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